Towels of micro fibers of polyester/polyamide bi-components and the method of making

ABSTRACT

A fabric with polyester/polyamide bi-components microfibers may include a warp knitted double-sided base fabric with polyester/polyamide bi-components microfibers that is treated by a chemical splitting process. Both sides of the double-sided base fabric may have at least 10 loop piles per square centimeter. Each loop pile may have at least one single thread loop. The bottom of the loop piles may be connected to the base fabric. The loops may be arranged orderly to form a planar structure that has the feature that the loop piles on one side of the base fabric may have plush-like structures at the top sections. The loops may be fractured by sanding the loops with a sand paper of 200-600 grits at about 1/10 to 5/10 of a thickness of the loop piles to form the plush-like structures.

TECHNICAL FIELD

This invention is related to towels of polyester/polyamide bi-components micro fibers and is in the field of textile fabrics.

BACKGROUND

It is well known that the traditional towels are made of natural fibers: for example cotton fibers. Cotton fibers may facilitate the propagation of bacteria and mildew in a humid environment. In addition, traditional towels may lose fibers quickly and may become stiff after being washed.

Micro fibers have the advantages of extra high absorbency, resistance to tinting, resistance to mildew growth, odorless, softness, resistance to color fading, easy to clean after usage, resistance to chlorine bleaching and oxidizing bleaching, etc. They are widely used and have great performance in automobile maintenance, hotel industry, beauty salons, sports products and products for daily use. Examples of products with micro fibers may include towels, shower towels, hair-drying bath hats, facial cleaning cloths, household cleaning cloths, and automobile cleaning cloths, etc.

The advantages of micro fibers are as follows: because the micro fibers have very large specific surface areas, the fibers have extremely large surface area coverage. Micro fibers also have greater chances of contacting dusts or grease, and at the same time grease may have greater chances of infiltrating into the gaps on the surfaces of the micro fibers; therefore they have superior cleaning capability. Fabrics with micro fibers may also penetrate deeply into the pores on the skin and efficiently clean dirt, grease, dead skin, and residuals of cosmetics. Because the diameter of a micro fiber is very tiny, its bending stiffness is very small; therefore micro fibers are very soft. Gaps of the neighboring fibers of ultra-dense fabrics made of micro fibers may have a diameter that is between the diameter of a water drop and a micro-drop of water vapor; therefore the ultra-dense fabrics made of micro fibers may have the quality of resistance to wetting and breathability. Fabrics made of micro fibers can also overcome the disadvantages of the poor wrinkle-resistance of natural fibers, and the poor breathability of other man-made fibers. These fabrics may last more than four times over the normal fabrics. Micro fibers have broad scopes of applications in the future.

To make micro fibers with polyester/polyamide bi-components, the segments are separated by dissolving one of the components, and then extruded through a spinneret capillary. The cross section of the fibers may have a unique shape such as a segmented pie or citrus type. After the fabricating process, the fibers may go through a splitting process in an about 5% alkali solution at 110° C. to peel off the polyester and polyamide, so that micro fibers may be formed. Normal micro fibers have a double-sided loop piles structure. After only one splitting process, the diameter of each fiber is only about 0.1D. Therefore, the normal fabric has high frictional drag during usage. It is not smooth and easily to scratch one's hands, so it gives people an uncomfortable feeling. Especially when the skin is dry or coarse, the uncomfortable feeling is more prominent. All these restrict the further development of fabrics made of micro fibers.

Chinese Patent CN200910260596.8 discloses a method of napping fibers of artificial leather: peach one side or both sides of the artificial leather made from micro fibers of polyurethane so that the micro fibers of polyester and polyamide on the surface(s) of the leather may curl up to form polyester fluff and polyamide fluff. This napping method can simultaneously maintain the properties of both types of micro fibers so that the final product has the properties of both stiffness and softness, and the leather may give people fine hand feel. This napping method is directed to plain weave.

An article by Weiyong Li (Development of Raised Sea-Island Bi-components Micro Fiber Products, Silk, 2004 (12): 7-9) discloses that the parameters of the napping treatment of the fabrics may be changed based on the types and styles of the raised sea-island bi-components micro fiber products. The main factors affecting the napping treatment are: the grit number of the sanding paper, the rotation speed of the sanding paper, wrapping angle, the speed of the advancement of the fabric, the moisture content of the fabric and the after-napping treatment methods. The techniques of the napping method affect the style and appeal of the fabric. The familiarity of the operation of the napping machine is critical to get the desired napping effect. It is also important to modify the napping techniques according to the situations. For example, if new sanding paper is used, smaller wrapping angle and faster fabric advancing speed may be used. However, after the sanding paper being used for a period of time, bigger wrapping angle and tension, as well as lower fabric advancing speed should be used so that the napped fabric may have consistent surface characteristics. One example of napping method is: 240-280 grits sanding paper is used, the rotation speed of the sanding paper is 800-1000 rpm, and the fabric advancing speed is 20-25 meters/min. This method is also directed to plain weave.

SUMMARY

This invention is intended to provide a towel of polyester/polyamide bi-components micro fibers that have an outward plush-like structure at the top sections of the loop piles of fibers on at least one side of the towel. The towels made of these fibers are more comfortable to touch, capable of keeping the heat, skin-friendly, high absorbency, soft and strong.

A towel of polyester/polyamide bi-components micro fibers according to this invention includes a wrap knitted double-sided base fabric of polyester/polyamide bi-components micro fibers that is treated by a chemical splitting process. Both sides of the double-sided base fabric have at least 10 loop piles per square centimeter. Each loop pile may have at least one single thread loop. The bottoms of the loop piles may be connected to the base fabric. The loops of the loop piles may be arranged orderly to form a planar structure having the feature that at least the loop piles on one side of the base fabric may have plush-like structures at the top sections of the loop piles. The plush-like structures may be formed by fracturing the loops of the loop piles from the top of the loops of the loop piles inwardly to about 1/10 to 5/10 of a thickness of the loop piles form the top of the loop piles. The fractured loops may form outward plush-like structures. In one embodiment, the sanding paper used for the sanding treatment may be 200-600 grits; the rotation speed of the sand paper may be 600 to 1500 rpm; the speed of fabric advancement may be 2 to 15 meters per minute, and the sanding angle may be 5 to 70 degrees.

In one preferred embodiment, the loop piles on both sides of the double-sided base fabric may have the plush-like structures at the top sections of the loop piles. The positions of the loops of the loop piles that are fractured may be the same or different on the two sides.

In one preferred embodiment, the plush-like structure may be made by fracturing the loops from the top of the loop piles inwardly to about ⅓ of the thickness of the loop piles from the top of the loop piles.

The sanding process may be accomplished with a typical fabric sanding machine.

The properties of the method mentioned above may be as follows: for the towels of polyester/polyamide bi-components micro fibers according to this invention, the loop piles on at least one side of the base fabric may have an outward plush-like structure at the top sections of the loop piles. The plush-like structure is formed by fracturing the loops of the loop piles from the top of the loop piles to about 1/10 to 5/10 of the thickness of the loop piles.

In a preferred embodiment, both sides of the base fabric may be sanded. The locations of the sanding process may be the same or different for the two sides. The sanding positions on the thickness of the loop piles may affect the length of the plush-like structure.

In a preferred embodiment, the position of the sanding is from the top sections of the loop piles inwardly to about ⅓ of the thickness of the loop piles. In one embodiment, the fibers of polyester/polyamide bi-components may be formed by four long yarns or threads. Two center threads may be polyester fibers, and the two side fibers may be polyester/polyamide bi-components fibers. The center threads may form the base fabric and the side polyester/polyamide bi-components fibers form the loop piles. The composition of the polyester/polyamide bi-components may be 80% polyester: 20% polyamide, 70% polyester: 30% polyamide, or 85% polyester: 15% polyamide.

In one embodiment, the composition of the base fabric may have polyester up to 70-90% of the total weight, and polyamide up to 10-30% of the total weight.

A method of printing towels of polyester/polyamide bi-components micro fibers may include: warp knitting fabrication - - - high temperature fixing at 210 degrees Celsius - - - chemical splitting - - - bleaching - - - drying/fixing at 160 degrees Celsius - - - napping process - - - rinsing - - - drying/fixing at 160 degrees Celsius - - - printing - - - drying at 160 degrees Celsius - - - color fixing at 170 degrees Celsius - - - rinsing - - - drying/fixing at 160 degrees Celsius - - - pattern cutting - - - sewing - - - quality examination/packaging.

A method of dying towels of polyester/polyamide bi-components micro fibers may include: wrap knitting fabrication - - - high temperature fixing at 210 degrees Celsius - - - chemical splitting - - - dying - - - drying/fixing at 160 degrees Celsius - - - napping process - - - rinsing - - - drying/fixing at 160 degree Celsius - - - quality examination/packaging.

Fabrics may be treated with various dying or printing techniques according to different requirements.

The advantages of this invention may be as follows: for the method of making towels of polyester/polyamide bi-components micro fibers according to this invention, the loop piles on at least one side of the base fabric may be fractured from the top of the loop piles and move inwardly to about 1/10 to 5/10 of the thickness of the loop piles. The fabric may have an outward plush-like structure at the top section of the loop piles. This method is simple and effective, and easily to implant. The fabrics may be more comfortable to touch, capable of keeping the heat, skin-friendly, high absorbency, soft and strong.

DRAWINGS

FIG. 1 shows the structure of the micro fibers according to one embodiment of this invention.

-   -   1. plush-like structure, 2. base fabric, 3 loop piles.

DETAILED DESCRIPTION

The technique scheme of the invention is further described hereinafter by combing the embodiments and the FIGURE.

In one embodiment, the fibers of polyester/polyamide bi-components may be formed by four threads. Two center threads may be polyester threads, and the two side threads may be polyester/polyamide bi-components micro fibers. The center threads may form the base fabric and the side polyester/polyamide bi-components micro fibers form the loop piles. The composition of the polyester/polyamide bi-components may be 80% polyester: 20% polyamide.

The towels may be finished with a dying process: wrap knitting fabrication - - - high temperature fixing at 210 degrees Celsius - - - chemical splitting - - - dying - - - drying/fixing at 160 degrees Celsius - - - napping process - - - rinsing - - - drying/fixing at 160 degree Celsius - - - quality examination/packaging.

Example 1

As shown in FIG. 1, in one embodiment, a towel of polyester/polyamide bi-components micro fibers may be a wrap knitted fabric that has a double-sided base fabric 2 made of polyester/polyamide bi-components micro fibers that are treated by a chemical splitting process. Both sides of the base fabrics 2 may have loop piles 3. The density of the loop piles 3 may be at least 10 per square centimeter. Every loop pile 3 may contain at least 1 single-thread loop. The bottom sections of loop piles 3 are connected to the base fabric 2. A plush-like structure 1 may be made by fracturing loops from the top of the loop piles 3 inwardly to about ⅓ of the thickness of the loop piles 3 from the top of the loop piles 3. All the loop piles 3 may have loops fractured at about the same position. The fractured fibers may form an outward plush-like structure 1. The sanding paper used for the sanding treatment may be 400 grits. The rotation speed of the sand paper may be 1000 rpm, and the speed of fabric advancement may be 15 meters per minute, and the sanding angle may be 40 degrees. The advantages of the towels made from the above mentioned method may be that every loop pile 3 may have outward plush-like structures 1 from the top of the loop piles 3. The plush-like structures 1 may be made by fracturing loops from the top of the loop piles 3 inwardly to about ⅓ of the thickness of the loop piles 3. All the loop piles may have loops fractured at about the same position.

The composition of the polyester/polyamide bi-components of the towels may be 88% polyester: 12% polyamide.

The test results of the towels of example 1 are shown in Table 1.

TABLE 1 Experimental Data of a Sample Grading of Tested Properties Inspection Criteria Standards Colorfastness to Washing 4.5 AATCC 61-2010 Colorfastness to Light 4   AATCC 16-2004 Colorfastness to Water 4.5 AATCC 107-2009 Colorfastness to Perspiration 4.5 AATCC 106-2009 Absorbency 58%  ASTM D4772-1997

The test results show that the colorfastness and the absorbency of the sample all meet the standards.

Example 2

As shown in FIG. 1, in one embodiment, a towel of polyester/polyamide bi-components micro fibers may be a wrap knitted fabric that has a double-sided base fabric 2 made of polyester/polyamide bi-components micro fibers that are treated by a chemical splitting process. Both sides of the base fabrics 2 may have loop piles 3. The density of the loop piles 3 may be at least 10 per square centimeter. Every loop pile 3 may contain at least 1 single-thread loop. The bottom sections of loop piles 3 are connected to the base fabric 2. Only the loop piles 2 on one side of the base fabrics 2 are sanded. The sanding process may start at the top of the loop piles 3 and moves inwardly to about 1/10 of the thickness of the loop piles 3. The fractured loops of the loop piles 3 may form outward plush-like structures 1. The sanding paper used for the sanding treatment may be 500 grits. The rotation speed of the sand paper may be 1200 rpm, and the speed of fabric advancement may be 10 meters per minute, and the sanding angle may be 5 degrees.

The advantages of the towels made from the above mentioned method may be that every loop piles 3 may have outward plush-like structures 1 at the top of the loop piles 3. The plush-like structures 1 may be made by fracturing loops from the top to about 1/10 of the thickness of the loop piles 3 from the top.

The composition of the polyester/polyamide bi-components of the towels may be 95% polyester: 5% polyamide.

The test results of the towels of example 2 are shown in Table 2.

TABLE 2 Experimental Data of a Sample Grading of Tested Properties Inspection Criteria Standards Colorfastness to Washing 4   AATCC 61-2010 Colorfastness to Light 4.5 AATCC 16-2004 Colorfastness to Water 4.5 AATCC 107-2009 Colorfastness to Perspiration 4.5 AATCC 106-2009 Absorbency 57.2% ASTM D4772-1997

The test results show that the colorfastness and the absorbency of the sample all meet the standards.

Example 3

As shown in FIG. 1, in one embodiment, the loop piles 3 of the both sides of the base fabric 2 may be sanded. On one side, the sanding process may start at the top of the loop piles 3 and moves inwardly to about 5/10 of the thickness of the loop piles 3 from the top. The sanding paper used for the sanding treatment may be 300 grits. The rotation speed of the sand paper may be 800 rpm, and the speed of fabric advancement may be 8 meters per minute, and the sanding angle may be 70 degrees. On the other side, the sanding process is started at the top of the loop piles 3 and moves inwardly to about 1/10 of the thickness of the loop piles 3. The sanding paper used for the sanding treatment may be 500 grits. The rotation speed of the sand paper may be 1200 rpm, and the speed of fabric advancement may be 10 meters per minute, and the sanding angle may be 5 degrees.

The advantages of the towels made from the above mentioned method may be that the loop piles on both sides of the base fabric 2 may have outward plush-like structures 1 at the top of the loop piles 3. The fractured positions on the loop piles are different, on one side the fractured position is at about 5/10 of the thickness and on the other side the fractured position is at about 1/10.

The composition of the polyester/polyamide bi-components of the towels may be 80% polyester: 20% polyamide.

The test results of the towels of example 3 are shown in Table 3.

TABLE 3 Experimental Data of a Sample Grading of Tested Properties Inspection Criteria Standards Colorfastness to Washing 4.5 AATCC 61-2010 Colorfastness to Light 4.5 AATCC 16-2004 Colorfastness to Water 4.5 AATCC 107-2009 Colorfastness to Perspiration 4.5 AATCC 106-2009 Absorbency 57.7% ASTM D4772-1997

The test results show that the colorfastness and the absorbency of the sample all meet the standards.

Example 4

As shown in FIG. 1, in one embodiment, the loop piles 3 of the both sides of the base fabric 2 may be sanded. The sanding positions are the same on both sides. The sanding process may start at the top of the loop piles 3 and moves inwardly to about 4/10 of the thickness of the loop piles 3 from the top of the loop piles 3. The sanding paper used for the sanding treatment may be 400 grits. The rotation speed of the sand paper may be 900 rpm, and the speed of fabric advancement may be 8 meters per minute, and the sanding angle may be 50 degrees.

The properties of the towels made from the above mentioned method may be that the loop piles on both sides of the base fabric 2 may have outward plush-like structures 1 at the top of the loop piles 3. The fractured positions on the loop piles are at about 4/10 of the thickness. The fractured positions are about the same.

The composition of the polyester/polyamide bi-components of the towels may be 70% polyester: 30% polyamide.

The test results of the towels of example 4 are shown in Table 4.

TABLE 4 Experimental Data of a Sample Grading of Tested Properties Inspection Criteria Standards Colorfastness to Washing 4   AATCC 61-2010 Colorfastness to Light 4.5 AATCC 16-2004 Colorfastness to Water 4.5 AATCC 107-2009 Colorfastness to Perspiration 4.5 AATCC 106-2009 Absorbency 57.9% ASTM D4772-1997

The test results show that the colorfastness and the absorbency of the sample all meet the standards. 

1. A method of making fabric with polyester/polyamide bi-components microfibers comprising: providing a two-sided base fabric with polyester/polyamide bi-components microfiber, each side of the base fabric including loop piles in a density of at least 10 loop piles per square centimeter, each loop pile including one or more single thread loops, and bottoms of the loop piles connected to the base fabric; and sanding the loop piles on at least one side of the base fabric, wherein the sanding step starts at a top of the loop piles and move inwardly till about 1/10 to 5/10 of a thickness of the loop piles, the sanding step uses a sanding paper of a sanding paper of 200 to 600 grits, a rotation speed of the sanding paper of about 600 to 1500 rpm, a speed of the base fabric advancing speed of about 2 to 15 meters/min, and a sanding angle of about 5 to 70 degrees.
 2. The method of claim 1 further comprising sanding the loop piles on the other side of the base fabric.
 3. The method of claim 1 wherein positions of the sanding step are the same or different for the loop piles on both sides of the base fabric.
 4. The method of claim 2 wherein positions of the sanding step are the same or different for the loop piles on both sides of the base fabric.
 5. The method of claim 1 wherein the sanding process moves till about ⅓ of a thickness of the loop piles from the top of the loop piles.
 6. A fabric with microfibers made with the method of claim 1 comprising: loop piles at least on one side of the fabric having outward plush-like structures, wherein the outward plush-like structures are formed by fractured loops of the loop piles at about 1/10 to 5/10 of the thickness of the loop piles from the top of the loop piles.
 7. The fabric of claim 5, wherein both sides of the fabric have outward plush-like structures, fractured positions on the loop piles are different on the both sides of the fabric.
 8. The fabric of claim 5, wherein both sides of the fabric have outward plush-like structures, fractured positions on the loop piles are the same on the both sides of the fabric.
 9. The fabric of claim 5, loop piles at least on one side of the fabric having outward plush-like structures, wherein the outward plush-like structures are formed by fractured loops of the loop piles at about ⅓ of the thickness of the loop piles from the top of the loop piles. 